Max-Air Systems MA-35 User manual

USE AND MAINTENANCE MANUAL
MA-35
0
•
Rev. 6-28-21

17
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1
2
3
6
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9
12
13
14
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15
16
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Non‐continuousduty‐donotuseonairstoragecylinders
Usetwistlock
p
lu
g
rated
@15am
p
sfor230v
@30am
p
sfor120v
minimum
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 
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1. 3 HP electric motor, single phase with On/Off switch (full load amps – 230 volt 15 amps – 120 volt 30 amps @ 3000psi)
2. Compressor heads, air cooled, 4 stages of compression
3. Purification chamber
4. Purification cap, unscrew counterclockwise for filter removal – Make sure power is off and #5 and #6 are open prior to attempting to
remove cap – use LF-1001 purification disposable cartridge only – read instructions on cartridge
5. Purification drain tap – slowly open to drain every 20 minutes – if you get moisture you are not draining #6 sufficiently.
6. Moisture oil/vapor separator, drain every 10 minutes or more often if in hot and humid climate.
7. Separator
8. Purified air outlet – screw on fill hose assy (not shown) snuggly (NO TEFLON TAPE NEEDED) will accept
SCUBA and SCBA fill hose assy with On/Off bleed valve
9. Pressure maintaining valve to assure proper filtration and air quality. Will not open until compressor reaches 1600/1800 psi
10. Final pressure gauge – oil bubble is for contraction and expansion of shock dampening oil.
DO NOT OPERATE COMPRESSOR WITHOUT IT.
12. Final safety relief valve, factory preset to 3300 psi for SCUBA – 10% above the average scuba cylinder, cylinder or compressor must
be turned off at rated pressure - 3000psi for SCUBA to avoid overworking relief valve.
DO NOT ATTEMPT RE-ADJUSTING.
13. Oil drain – not shown on side of crankcase – run unit 2 minutes and elevate opposite end for quicker drainage
14. Oil fill and dip stick – simply pull up, pour oil in slowly (capacity 12 oz) - use MaxLube 501 synthetic breathing compressor oil only.
Change out break in oil after 15 hours – replace with MaxLube 501 provided, then every 50 hours thereafter.
15. Crankcase vent, remove cap prior to refilling oil & replace prior to start after oil changes
16. Fan guard – DO NOT REMOVE
17. Belt guard – DO NOT OPERATE WITHOUT (see manual for belt tension)
18. Retractable handle – can be removed for storage by loosening (2) retaining screws on retainer
NOTES: (the below rating A & B is based on a 80cft cylinder @ 3000 psi)
A. The LF-1001 filter is rated for 2,440 cft of grade “E” air @ 72
o
F intake temperature, draining the condensate
often = prox. 30 cylinders. For hot and humid climates you must de-rate by 10% for every 5
o
above 72
o
F.
B. In order to keep the amps draw at a minimum the fill time is approx 15% longer than gas driven units.
Date:
Max‐Air
2807PeddlerLane
Kerrville,Texas78028
830‐955‐8188/830‐257‐3720Fax
E‐mail:sales@max‐air.com
www.max‐air.com
Finalsafetyreliefvalve
presetfor:_________psi
Serial#: __________
10
11
5
18
4

8


11. Intake air filter behind pressure gauge.
7
MA 35 ELEC 1PHASE 3PHASE 120 VAC 230 VAC 60 HZ 50 HZ
MA 35 Gas Honda MA 35 Gas Subaru

P
ersonal,portable,highpressurebreathingaircompressor
Page 1 of 61

Dear Customer,
is provided together with the compressor to aid you in the use of the
machine and ensure that your work produces the best possible results.
Please read all the instructions and information provided on the following
pages. Ensure that the manual is at the disposal of the personnel who will
be using/managing the compressor and carrying out any maintenance on
it.
Should you require any clarication, when using the compressor for the rst
HIGH PRESSURE COMPRESSORS
IMPORTANT: BEFORE USING THE COMPRESSOR READ THIS
MANUAL CAREFULLY.
FOR PURE BREATHING AIR AND TECHNICAL GASES
time or at any other time it is used, please remember that Max-Air is at
able to provide you with assistance and spare parts as and when required.
For routine or unscheduled maintenance note that Max-Air technical service is
your complete disposal.
To ensure that your requests are handled quickly, the following
information is provided:
Page 2 of 61
Thank you for choosing a Max-Air compressor. This manual
WARNING:
The compressors are delivered without the rell hoses,
compressor lubricating oil, combustion engine lubricating
oil or ltration cartridge: these items are supplied inside the
packaging.
IMPORTANT: BEFORE CARRYING OUT ANY WORK ON
THE ENGINE CONSULT THE ATTACHED ENGINE USE AND
MAINTENANCE MANUAL.
WARNING:This is a non-continuous duty compressor. It
is recommended when filling,to only fill one tank at a
time. For all operations, the continuous run time should
never exceed 45 minutes. A minimum cool down period
of 30 minutes should be given for every 45 minutes of
operation.

supplied with the compressor (see section “7.6”).
- Check that the cartridge is inside the ltration cartridge (see chap“7.10”).
For compressors with combustion engines:
For compressors with electric motors:
- For compressors equipped with a three-phase electric motor, check
that the cooling fan rotates in the direction indicated by the arrow on
- Switch on the compressor with the ll valve 1 connected to the closed
bottle 2 and the condensate outlets 3 closed and check that free drainage
of the safety valve occurs when the value on the gauge is the same as the
calibration value of the valve (see section “6.2.4”).
Bottle rell (see section “6.4”):
- t the hose connector 1 on the bottle connector 2 (closed);
- open the condensate discharge valve 3 on the separator;
- start the compressor;
- close the discharge;
- open the tank valve 4;
- discharge the condensate every 10-15 minutes of use.
QUICK GUIDE
WARNING:
- This guide is intended only as a rapid introduction to use of
the compressor.
-This guide is not meant to replace the use and maintenance
manual.
- This compressor must not be used before reading the
entire use and maintenance manual.
the cover; if it turns the other way reverse two of the three phases on the
main power (see section “6.1.4”).
- Check fuel level and top off if necessary (see section “7.7”).
-
A dedicated 35 amp breaker is required for this compressor.
Connect the electric motor to the main power (see section "5.3.3").
Preliminary tasks:
- Position the compressor in the selected area (see section “5”).
- If necessary connect the air intake extension (see section “5.3.2”).
- Connect the rell hoses (see section “6.1.5”).
- Check the oil level; if the compressor is new ll the oil sump with the oil
Page 3 of 61

CA
AC
a) Start
b) Stop
a
4
1
b
a
ba
2
b
3
3
“7.10”).
section “7.11”).
- Periodically change the hoses (see section “7.12”).
Page 4 of 61
When rell is complete:
- switch o the compressor;
- close the bottle valve 4;
- open the condensate discharge valve 3 and let all the air bleed out;
- disconnect the coupling 1 from the bottle.
Maintenance:
- After the rst 12working hours change the oil again (see section “7.6”).
- Check the lubricating oil level every 5 hours (see section “7.6”).
- Change the lubricating oil every 50 hours (see section “7.6”).
- Periodically change the air intake lter (see section “7.8”).
- Discharge the condensate (see section “7.9”).
- Periodically change the ltration cartridge (see section
- Check transmission belt tension and if necessary change it (see

CONTENTS
1 - GENERAL 7
1.1 Preliminary information 7
1.2 Required operator training 7
1.3 Important information for the user 7
1.4 Foreword 8
1.5 Warranty 9
1.6 Assistance 10
1.7 Responsibility 10
1.8 Purpose of the machine 11
1.9 Where the machine may be used 13
1.10 Running in and testing the compressor 13
1.10.1 Tightening torque values 14
2 - BASIC INFORMATION ONTHE COMPRESSOR 14
2.1 Description of the compressor 14
2.2 General instructions 15
3 - SAFETY REGULATIONS 16
3.1 General safety rules 16
3.1.1 Know the machine 16
3.1.2 Protective clothing16
3.1.3 Emergency equipment 16
3.1.4 Checks and maintenance 16
3.2 General precautions 17
3.2.1 Important safety information 19
3.2.2 Accident prevention 19
3.2.3Working safety 19
3.2.4 Noise level 19
3.2.5 Residual risk zones 19
3.3 Safety info labels: location 20
3.3.1 Safety info labels: description 21
3.4 General safety regulations 23
3.4.1 Care and maintenance 23
3.4.2 Fire extinguishers and rst aid 23
3.5 Maintenance precautions 24
3.5.1 Periodic replacement of essential safety parts 24
3.5.2Tools 24
3.5.3 Personnel 24
3.5.4 Keeping the compressor clean 25
3.5.5Warning signs 25
4 - TECHNICAL DATA 26
4.1 Technical characteristics 26
4.1.1 Crankcase, crankshaft, cylinder, piston 26
4.1.2 Valves 26
4.1.3 Safety valves 26
4.1.4 Lubrication 26
4.1.5 Cooling tubes 26
4.1.6 Frame, guards 26
4.1.7 Pressure gauges 26
4.2 Machine parts 27
4.3 Technical characteristics 28
4.4 Pressure circuit 30
5 - HANDLING AND INSTALLATION 31
5.1 Unpacking 31
5.2 Handling 31
5.3 Installation 32
5.3.1 Positioning 32
5.3.2 Air intake extension connection 33
5.3.3 Electrical connection 33
34
34
6.1.5 Rell hoses connection 35
6 - USING THE COMPRESSOR 34
6.1 Preliminary checks before using for the rst time 34
6.1.1 Filling with lubricating oil 34
6.1.2 Inserting ltration cartridge 34
6.1.3 Filling the engine with lubricating oil
(for internal combustion engine only)
6.1.4 Checking for proper electrical connection
(for three-phase electric motor only)
Page 5 of 61

6.2 Checks to be run at the start of each working day 35
6.2.1 Lubricating oil level check 3 5
6.2.2 Checking that the ex hoses are in good condition 3 6
6.2.3 Fuel level check 3 6
6.2.4 Checking the safety valves 3 6
6.2.5 Storing technical documentation 3 7
6.3 Starting and shutting down 3 7
6.3.1Startingandshuttingdownwithinternal combustion engine 3 7
6.3.2 Starting and shutting down with electric motor 3 8
6.4 Tank rell 3 9
6.5 Optional 4 2
6.5.1 Automatic shutdown with pressure switch 4 2
6.5.2 Automatic condensate discharge 4 2
6.5.3 Hour counter 4 2
9 - DISMANTLING AND PUTTING OUT OF SERVICE 5 5
9.1 Waste disposal 5 5
9.2 Dismantling the compressor 5 7
8 - STORAGE 5 4
8.1 Stopping the machine for a brief period 5 4
8.2 Stopping the machine for a long period 5 4
7 - MAINTENANCE 4 2
7.1 Foreword 4 3
7.2 General 4 3
7.3 Unscheduled work 43
7.4 Scheduled maintenance table 4 4
7.5 Troubleshooting 45
7.6 Checking and changing the lubricating oil 4 6
7.7 Checking fuel level and topping up 4 8
7.8 Changing the intake lter 4 8
7.9 Condensate discharge 4 9
7.10 Purier lter 50
7.11 Transmission belt 5 2
7.12 Changing the ex hose 5 3
10 - MAINTENANCE REGISTER 5 7
10.1 Assistance service 5 7
10.2 Scheduled maintenance 5 8
10.3 Using the compressor under heavy-duty conditions 5 8
10.4 The Customer Care Cent er 5 8
10.5 Scheduled maintenance registry coupons 5 9
Page 6 of 61

1 – GENERAL
1.3 IMPORTANT INFORMATION FOR THE USER
1.1 PRELIMINARY INFORMATION
1.2 REQUIRED OPERATOR TRAINING
Do not destroy or modify the manual and update it with inserts published
by producer only.
Machine type: High pressure compressor for breathing air
and/or technical gases
This manual must be read carefully:
-all compressor operators / maintenance personnel must read this entire
manual with due care and attention and observe the instructions/
information contained herein.
The information/instructions for compressor use contained in this manual
The instruction manual must be read and used as follows:
-read this manual carefully, treat it as an essential part of the compressor;
-the instruction manual must be kept where it can readily be consulted by
compressor operators and maintenance sta;
-keep the manual for the working life of the compressor;
-make sure updates are incorporated in the manual;
-make sure the manual is given to other users or subsequent owners in
the event of resale;
-keep the manual in good condition and ensure its contents remain
it is advisable to request a copy from the manufacturer.
Model: MA-35
e-mail: [e-mail]
http: www.max-air.com
Telephone: [phone]
Manufacturer’s data: Max-Air
2807 Peddler Lane
Kerrville, Tx 78028
only concern the Max-Air Model:
MA-35
undamaged;
-
do not remove, tear or re-write any part of the manual for any reason;
-
keep the manual protected from moisture and heat;
-
if the manual is lost or partially damaged and its contents cannot be read
-
the operator must possess the required training for operation of the
compressor and has taken the time to read the manual.
Page 7 of 61

IMPORTANT: Refers to additional information or suggestions
for proper use of the compressor.
WARNING: Refers to dangerous situations that may occur
during use of the compressor: aims to prevent damage to
objects and the compressor itself.
DANGER: Refers to dangerous situations that may occur
during use of the compressor: aims to ensure worker safety.
Important: you must understand the following symbols and their meaning.
They highlight essential information:
The regulations/instructions for use contained in this manual constitute an
essential component of the supplied compressor.
These regulations/instructions are intended for an operator who has
information necessary and essential to safety and ecient, proper use of
Before beginning work, read the following suggestions carefully:
- before using the compressor, gain familiarity with the tasks to be
completed and the admissible working position;
- program all work with due care and attention;
- you must have a detailed understanding of where and how the
compressor is to be used;
- before starting work make sure that safety devices are working properly
and that their use is understood; in the event of any doubts do not use
the compressor;
- constant and careful preventive maintenance will always ensure a high
level of safety when using the compressor. Never postpone repairs and
spare parts.
1.4 FOREWORD
the compressor. Hurried or careless preparation leads to improvisation,
which is the cause of accidents.
already been trained to use this type of compressor. They contain all the
- the operator must always have the instruction manual on hand;
have them carried out by specialized personnel only; use only original
- observe the warnings given in this manual with due care and attention;
Page 8 of 61

The warranty does not cover faults caused by improper use of the
transport; all materials subject to wear and those subject to periodic
Routine and unscheduled maintenance must be carried
out in compliance with the instructions contained in this
manual. Should the required work not be covered by the
manual or assistance be required you are advised to contact
1.5 WARRANTY
maintenance are not covered by the warranty and are to be paid for by the
IMPORTANT: The materials supplied by Max-Air are covered
by a 1 year warranty, the validity of which begins when the
compressor is put into service as proven by the delivery
document.
Max-Air shall repair or replace those parts it acknowledges
to be faulty during the warranty period.
In replacing the faulty part Max-Air shall not be liable for
any other expenses sustained by the dealer or his customer
such as presumed damage (present or future), lost earnings
or nes.
Max-Air in writing, even where agreements have already
been made on the phone. Max-Air cannot be held liable for
any delays or failure to execute work.
Max-Air cannot be held liable for any damage or mal-
functions caused by work carried out on the compressor by
unauthorised personnel.
compressor, exposure to atmospheric agents (rain etc.) or damage during
Max-Air guarantees that its compressors are free from design defects,
workmanship and the used materials for a period of 1 year starting
from the date of delivery of the compressor; should the customer
note any aws and/or defects he must report them, in writing via email , to
Max-Air within 7 days of delivery otherwise the warranty shall be rendered
null and void. The warranty only covers flaws and faults that occur
where the compressor is used properly in compliance with the instructions
contained in this manual and where periodic maintenance is carried out.
Page 9 of 61